TOYOTA AVENSIS 2003 Service Repair Manual

G23226Lithium soap base glycol grease
Cylinder Boot
Piston
G23225
Cylinder Boot
Piston
F45418
F45420
Front Disc Brake Cylinder MountingBush Dust Boot
Lithium soap base glycol grease
32±44
±
BRAKE FRONT BRAKE
AVENSIS REPAIR MANUAL (RM1018E)
18. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG
(a) Temporarily install the front disc brake bleeder plug to the disc brake c\
ylinder assy LH.
(b) Install the bleeder plug cap to the bleeder plug.
19. INSTALL PISTON SEAL
(a) Apply lithium soap base glycol grease to a new piston seal.
(b) Install the piston seal to the disc brake cylinder assy LH. 20. INSTALL FRONT DISC BRAKE PISTON
(a) Apply lithium soap base glycol grease to the front discbrake piston and a new cylinder boot.
(b) Install the cylinder boot to the front disc brake piston.
(c) Install the piston to the disc brake cylinder assy LH.
NOTICE:
Do not install the piston forcibly in the disc brake cylinder.
21. INSTALL CYLINDER BOOT
(a) Using SST and a hammer, install the cylinder boot to the disc brake cylinder assy LH.
SST 09550±60010
NOTICE:
Do not damage the cylinder boot.
HINT:
Install the boot securely to the disc brake cylinder assy LH.
22. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING
LH
(a) Install the front disc brake cylinder mounting LH with the 2 bolts.
Torque: 102 N
m (1,040 kgf
cm, 75 ft
lbf)
23. INSTALL FRONT DISC BRAKE BUSH DUST BOOT
(a) Apply lithium soap base glycol grease to the sealing sur- face of 2 new front disc brake bush dust boots.
(b) Install the 2 front disc brake bush dust boots to the front disc brake cylinder mounting LH.
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F45419
Cylinder Slide Pin
Lithium soap base glycol grease
F45421
Union Bolt
±
BRAKE FRONT BRAKE
32±45
AVENSIS REPAIR MANUAL (RM1018E)
24. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN
KIT
(a) Apply lithium soap base glycol grease to the a new front
disc brake cylinder slide bush.
(b) Install the front disc brake cylinder slide bush to the bot- tom side of the front disc brake cylinder slide pin (No.2).
(c) Apply lithium soap base glycol grease to the sliding part
and the sealing surface of the 2 cylinder slide pins.
(d) Install the 2 front disc brake cylinder slide pins to the front disc brake cylinder mounting LH.
25. INSTALL FRONT DISC BRAKE PAD KIT
(a) Install the 2 front disc brake pad support plates (No.1) and 2 front disc bra\
ke pad support plates (No.2) to the front disc brake cylinder mounting LH.
(b) Install the disc brake pad kit front to the front disc brake cylinder mo\
unting LH.
NOTICE:
There should be no oil or grease on the friction surfaces of the pads an\
d the disc.
26. INSTALL DISC BRAKE CYLINDER ASSY LH
(a) Install the disc brake cylinder assy LH with the 2 bolts.Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
(b) Install a new gasket and flexible hose with the union bolt.
Torque: 29 N
m (296 kgf
cm, 21 ft
lbf)
HINT:
Install the flexible hose lock securely in the lock hole in the disc
brake cylinder assy LH.
27.FILL RESERVOIR WITH BRAKE FLUID (See page 32±4)
28.BLEED MASTER CYLINDER (See page 32±4)
(a) w/o VSC: SST 09023±00100
(b) w/ VSC: SST 09023±38400
29.BLEED BRAKE LINE (See page 32±4)
30.CHECK FLUID LEVEL IN RESERVOIR (See page 32±4)
31. CHECK BRAKE FLUID LEAKAGE
32. INSTALL FRONT WHEEL
Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
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320GE±03
G23180

Gasket
Flexible Hose
30 (306, 22)
Disc Brake Cylinder
Assy Rear LH
Disc Brake
Pad Kit Rear


Non±reusable part
N
m (kgf
cm, ft
lbf) : Specified torque
Lithium soap base glycol grease
Rear Disc Brake
Bush Dust Boot
Rear Disc Brake
Pad Support Plate No.1
Rear Disc Brake
Cylinder Mounting LH
RearDisc
Brake Piston
Cylinder Boot


Piston Seal
Rear Disc Brake
Cylinder Slide Pin (No.2)
Bleeder Plug Cap
Rear Disc Brake
Bleeder Plug
Rear Disc Brake
Cylinder Slide Bush
Rear Disc Brake
Cylinder Slide Pin (No.1)
Rear Disc Brake
Bush Dust Boot
Rear Disc
Parking Brake Shoe
Adjusting Hole Plug
47 (475, 34)
30 (306, 22)
47 (475, 34)
29 (296, 21)
10 (102, 7)
Rear Disc Brake
Pad Support Plate No.2
Union Bolt






Bolt


Bolt
32±46
±
BRAKE REAR BRAKE
AVENSIS REPAIR MANUAL (RM1018E)
REAR DISC BRAKE
COMPONENTS
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320W0±01
G23181
Union bolt
G23224
F45701
Cylinder Slide Pin
F45417
Cylinder Slide Bush
Cylinder Slide Pin (No.2)
±
BRAKE REAR BRAKE
32±47
AVENSIS REPAIR MANUAL (RM1018E)
OVERHAUL
HINT:
Overhaul the RH side by using the same procedures as those for the LH side.
1. REMOVE REAR WHEEL
2. DRAIN BRAKE FLUID
NOTICE:
Wash the brake fluid off immediately if it adheres to any painted surface\
.
3. REMOVE DISC BRAKE CYLINDER ASSY REAR LH
(a) Remove the union bolt and gasket from the brake cylinderassy rear LH, then disconnect the flexible hose from the
disc brake cylinder assy rear LH.
(b) Hold the rear disc brake cylinder slide pin and remove the 2 bolts.
4. REMOVE REAR DISC BRAKE PAD KIT
(a) Remove the disc brake pad kit rear.
(b) Remove the 2 rear disc brake pad support plates No.1 and 2 rear disc brake pad support plates No.2 from the
rear disc brake cylinder mounting LH.
5. REMOVE REAR DISC BRAKE CYLINDER SLIDE PIN KIT
(a) Remove the rear disc brake cylinder slide pin (No.1) and rear disc brake cylinder slide pin (No.2) from the disc
brake cylinder mounting LH.
(b) Remove the rear disc brake cylinder slide bush from the bottom side of the rear disc brake cylinder slide pin (No.2).
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F45439
Front Disc Brake Cylinder MountingBush Dust Boot
F45704
F42270
G23222
G23223
32±48
±
BRAKE REAR BRAKE
AVENSIS REPAIR MANUAL (RM1018E)
6. REMOVE REAR DISC BRAKE BUSH DUST BOOT
(a) Remove the 2 rear disc brake bush dust boots from the rear disc brake cylinder mounting LH.
7. REMOVE REAR DISC BRAKE CYLINDER MOUNTING LH
(a) Remove the 2 bolts and rear disc brake cylinder mounting LH.
8. REMOVE REAR DISC BRAKE PISTON
(a) Place a shop rug between the rear disc brake piston and the disc brake cylinder assy rear LH.
(b) Use compressed air to remove the rear disc brake piston from the disc brake cylinder assy rear LH.
CAUTION:
Do not place your fingers in front of the piston when using
compressed air.
NOTICE:
Do not spatter the brake fluid.
9. REMOVE CYLINDER BOOT
(a) Using a screwdriver, remove the cylinder boot.
10. REMOVE PISTON SEAL
(a) Using a screwdriver, remove the piston seal.
NOTICE:
Do not damage the inner cylinder and cylinder groove.
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G23182
F45707
F41555
Matchmarks
±
BRAKE REAR BRAKE
32±49
AVENSIS REPAIR MANUAL (RM1018E)
11. REMOVE REAR DISC BRAKE BLEEDER PLUG
(a) Remove the bleeder plug cap and rear disc brake bleeder plug from the disc bra\
ke cylinder assy raer
LH.
12. INSPECT BRAKE CYLINDER AND PISTON
(a) Check the cylinder bore and piston for rust or scoring. 13. INSPECT REAR DISC BRAKE PAD KIT
(a) Using a ruler, measure the disc brake pad lining thick-ness.
Standard thickness: 10.0 mm (0.394 in.)
Minimum thickness: 2.0 mm (0.079 in.)
(b) Inspect the 2 rear disc brake pad support plates No.1 and 2 rear disc brake pad support plates No.2. Make sure that
they have sufficient rebound, no deformation cracks or
wear, and have had all rust, dirt and foreign particles
cleaned off.
14. INSPECT DISC THICKNESS
(a) Using a micrometer, measure the rear disc thickness.
Standard thickness: 10.0 mm (0.394 in.)
Minimum thickness: 9.0 mm (0.354 in.)
15. REMOVE PARKING BRAKE SHOE ADJUSTING HOLE PLUG 16. REMOVE REAR DISC
(a) Place matchmarks on the rear disc and the axle hub.
(b) Remove the rear disc.
17. INSTALL REAR DISC
(a) Aligning the matchmarks, install the rear disc.
HINT:
Select the installation position where the rear disc has the mini-
mum runout.
18. INSTALL PARKING BRAKE SHOE ADJUSTING HOLE PLUG
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F45708
F45750Lithium soap base glycol grease
Cylinder Boot
Piston
G23231Cylinder Boot
Piston
F45704
32±50
±
BRAKEREAR BRAKE
AVENSIS REPAIR MANUAL (RM1018E)
19.INSPECT DISC RUNOUT
(a)Temporarily fasten the rear disc with the hub nuts. Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
(b)Using a dial indicator, measure the disc runout 10 mm (0.39 in.) away from the outer edge of the rear disc.
Maximum disc runout: 0.15 mm (0.0059 in.)
(c)If the disc runout is maximum value or greater, check the
bearing play in the axial direction and check for the axle
hub runout (See page 30±2). If the bearing play and axle
hub runout are normal, adjust the disc runout or grind it
on a ºOn±carº brake lathe.
20. TEMPORARILY TIGHTEN REAR DISC BRAKE BLEEDER PLUG
(a) Temporarily install the rear disc brake bleeder plug to the disc brake cy\
linder assy rear LH.
21. INSTALL PISTON SEAL
(a) Apply the lithium soap base glycol grease to a new piston seal.
(b) Install the piston seal to the disc brake cylinder assy rear LH. 22. INSTALL REAR DISC BRAKE PISTON
(a) Apply lithium soap base glycol grease to the rear discbrake piston and a new cylinder boot.
(b) Install the cylinder boot to the rear disc brake piston.
(c) Install the piston to the disc brake cylinder assy LH.
NOTICE:
Do not install the piston forcibly in the disc brake cylinder.
23. INSTALL CYLINDER BOOT
(a) Using SST and a hammer, install the cylinder boot to the disc brake cylinder assy rear LH.
SST 09710±06051
NOTICE:
Do not damage the cylinder boot.
HINT:
Install the boot securely to the disc brake cylinder rear LH.
24. INSTALL REAR DISC BRAKE CYLINDER MOUNTING LH
(a) Install the rear disc brake cylinder mounting LH with the
2 bolts.
Torque: 47 N
m (475 kgf
cm, 34 ft
lbf)
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F45439
Front Disc Brake Cylinder MountingBush Dust Boot
Lithium soap base glycol grease
F45701
Cylinder Slide Pin
Lithium soap base glycol grease
G23181
Union bolt
±
BRAKEREAR BRAKE
32±51
AVENSIS REPAIR MANUAL (RM1018E)
25.INSTALL REAR DISC BRAKE BUSH DUST BOOT
(a)Apply lithium soap base glycol grease to the sealing sur-
face of 2 new bush dust boots.
(b)Install the 2 bush dust boots to the rear disc brake cylinder mounting LH.
26.INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN KIT
(a)Apply lithium soap base glycol grease to sealing surface of a new cylinder slide bush.
(b)Install the rear disc brake cylinder slide bush to the bottom side of the rear disc brake cylinder slide pin (No.2).
(c)Apply lithium soap base glycol grease to the sliding part and the sealing surface of the 2 rear disc brake cylinder
slide pins.
(d)Install the rear disc brake cylinder slide pin (No.1) and rear
disc brake cylinder slide pin (No.2) to the rear disc brake
cylinder mounting LH.
27.INSTALL REAR DISC BRAKE PAD KIT
(a)Install the 2 rear disc brake pad support plates No.1 and 2 rear disc brake pad\
support plate No.2 to the rear disc brake cylinder mounting LH.
(b)Install the disc brake pad kit rear to the disc brake cylinder mounting \
LH.
28.INSTALL DISC BRAKE CYLINDER ASSY REAR LH
(a)Install the disc brake cylinder assy rear LH with the 2 bolts.Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
(b)Install a new gasket and flexible hose with the union bolt. Torque: 29 N
m (296 kgf
cm, 21 ft
lbf)
HINT:
Install the flexible hose lock securely in to the lock hole in the
disc brake cylinder assy rear LH.
29.FILL RESERVOIR WITH BRAKE FLUID (See page 32±4)
30.BLEED MASTER CYLINDER (See page 32±4)
(a) w/o VSC: SST 09023±00100
(b) w/ VSC: SST 09023±38400
31.BLEED BRAKE LINE (See page 32±4)
32.CHECK FLUID LEVEL IN RESERVOIR (See page 32±4)
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32±52
±
BRAKE REAR BRAKE
AVENSIS REPAIR MANUAL (RM1018E)
33. CHECK BRAKE FLUID LEAKAGE
34. INSTALL REAR WHEEL Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
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320VV±01
G23167
F08657
BoltSST
SST
Bolt
±
BRAKE SKID CONTROL SENSOR
32±61
AVENSIS REPAIR MANUAL (RM1018E)
SKID CONTROL SENSOR
REPLACEMENT
HINT:
Replace the RH side by using the same procedures as those for the LH side.
1. REMOVE REAR WHEEL
2. DISCONNECT SKID CONTROL SENSOR WIRE
(a) Disconnect the connector from the skid control sensor.
3. REMOVE REAR DISC BRAKE CALIPER ASSY LH
(a) Remove the 2 bolts and rear brake caliper assy LH.
4. REMOVE REAR DISC
(a) place matchmarks on the rear disc and the axle hub.
(b) Remove the rear disc.
5.REMOVE REAR AXLE HUB & BEARING ASSY LH (See page 30±31) 6. REMOVE SKID CONTROL SENSOR
(a) Mount the rear axle hub in a soft jaw vise.
NOTICE:
Replace the axle hub assembly if it is dropped or receives
a strong shock.
(b) Using a pin punch and hammer, drive out the 2 pins andremove the 2 attachments from SST.
(c) Using SST and 2 bolts (Diameter: 12 mm, pitch: 1.5 mm), remove the skid control sensor from the rear axle hub.
SST 09520±00031 (09520±00040), 09521±00020, 09950±00020
NOTICE:

If the sensor rotor is damaged, replace the axle hub
assembly.

Do not scratch the contacting surface of the axle hub
and speed sensor.
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